skripsi oleh : agus saripudin 201210215213repository.ubharajaya.ac.id/1621/1/201210215213_agus...
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ANALISIS PENGENDALIAN KUALITAS PADA PROSESPERBAIKAN HIDROLIK DENGAN MENGGUNAKAN
METODE PDCA (PLAN DO CHECK ACTION)
DI PT. ANDALAN FLUID SISTEM
SKRIPSI
Oleh :
AGUS SARIPUDIN
201210215213
PROGRAM STUDI TEKNIK INDUSTRI
FAKULTAS TEKNIK
UNIVERSITAS BHAYANGKARA JAKARTA RAYA
2017
ANALISIS PENGENDALIAN KUALITAS PADA PROSESPERBAIKAN HIDROLIK DENGAN MENGGUNAKAN
METODE PDCA (PLAN DO CHECK ACTION)
DI PT. ANDALAN FLUID SISTEM
SKRIPSI
Oleh :
AGUS SARIPUDIN
201210215213
PROGRAM STUDI TEKNIK INDUSTRI
FAKULTAS TEKNIK
UNIVERSITAS BHAYANGKARA JAKARTA RAYA
2017
ANALISIS PENGENDALIAN KUALITAS PADA PROSESPERBAIKAN HIDROLIK DENGAN MENGGUNAKAN
METODE PDCA (PLAN DO CHECK ACTION)
DI PT. ANDALAN FLUID SISTEM
SKRIPSI
Oleh :
AGUS SARIPUDIN
201210215213
PROGRAM STUDI TEKNIK INDUSTRI
FAKULTAS TEKNIK
UNIVERSITAS BHAYANGKARA JAKARTA RAYA
2017
v
ABSTRAK
Agus Saripudin. 201210215213. Analisis Pengendalian kualitas Pada
Proses Perbaikan Hidrolik Dengan Menggunakan Metode PDCA (Plan Do Check
Action).
PT. Andalan Fluid Sistem merupakan suatu usaha yang bergerak dalam
bidang perawatan dan perbaikan hidrolik. Dalam penelitian tugas akhir ini
membahas berupa studi kasus tentang penerapan PDCA sebagai sistem
manajemen baru di PT. Andalan Fluid Sistem, yang bertujuan untuk
meningkatkan kualitas dan menurunkan atau meminimalisir angka kecacatan,
serta memberikan usulan perbaikan berdasarkan hasil penelitian kepada
perusahaan agar dapat meningkatkan kualitas produk. Dari hasil penelitian
diperoleh data ada 4 jenis cacat yang sering terjadi pada produk hidrolik dengan
tingkat kecacatan yaitu Baling dengan jumlah 23 pcs yang cacat dengan
persentase sebesar 37%, Dengan alat bantu statistic (Seventools) seperti diagram
Fishbone dapat diketahui beberapa faktor yang menyebabkan produk hidrolik
cacat diantaranya yaitu faktor manusia, mesin ,lingkungan dan metode. Usulan
perbaikan untuk pengendalian kualitas produk hidrolik yaitu adanya standarisasi
yang ketat terhadap kinerja mesin, yaitu dengan melakukan pemeriksaan mesin
atau melakukan controlling system untuk mengamati kinerja mesin saat beroperasi
dan melakukan bimbingan (training) kepada seluruh karyawan. Setelah dilakukan
perbaikan selama 3 bulan telah terjadi penurunan produk cacat baling dengan
jumlah sebanyak 9 pcs yang cacat dengan persentase sebesar 27%.
Kata kunci : Kualitas, PDCA, Seventools
Analisis Pengendalian..., Agus, Fakultas Teknik 2018
vi
ABSTRACT
Agus Saripudin. 201210215213. Quality Control Analysis On Hydraulik
Repair Process Using PDCA Method (Plan Do Check Action).
PT. Andalan Fluid Sistem is a business which is engaged in hydraulic
maintenance and repair. In this thesis research discusses a case study on the
application of PDCA as a new management system at PT.andalan fluids system,
which aims to improve quality and reduce or minimize disability numbers,
and provide suggestions for improvement based on the results of research to the
company in order to improve product quality. From the research results obtained
4 types of defects that often occur in hydraulic products with the level of disability
is Baling with the amount of 23 pcs are disabled with a percentage of 37%, With
statistical tools (Seventools) such as Fishbone diagram can be known several
factors that cause hydraulic products defects include human factors, machinery,
environment and methods. The proposed improvement for hydraulic product
quality control is a strict standardization of machine performance, by performing
a machine check or controlling system to observe the performance of the machine
while operating and conduct training to all employees. The proposed
improvement for hydraulic product quality control is a strict standardization of
machine performance, by performing a machine check or controlling system to
observe the performance of the machine while operating and conduct training to
all employees. After 3 months of improvement there has been a decline in
defective product of baling with a total of 9 pcs of defects with a percentage of
27%.
.
Keywords: Quality, PDCA, Seventools
Analisis Pengendalian..., Agus, Fakultas Teknik 2018
ix
DAFTAR ISI
Halaman
LEMBAR JUDUL ............................................................................................. i
LEMBAR PERSETUJUAN ............................................................................. ii
LEMBAR PENGESAHAN .............................................................................. iii
LEMBAR PERNYATAAN .............................................................................. iv
ABSTRAK ......................................................................................................... v
ABSTRACT ........................................................................................................ vi
KATA PENGANTAR ....................................................................................... vii
DAFTAR ISI ..................................................................................................... ix
DAFTAR TABEL ............................................................................................. xii
DAFTAR GAMBAR ......................................................................................... xiii
BAB I PENDAHULUAN
1.1. Latar Belakang Masalah .............................................................................. 1
1.2. Identifikasi Masalah ..................................................................................... 3
1.3. Perumusan Masalah ..................................................................................... 3
1.4. Batasan Masalah........................................................................................... 4
1.5. Tujuan dan Manfaat ..................................................................................... 4
1.6. Sistematika Penulisan .................................................................................. 5
BABII LANDASAN TEORI
2.1. Pengertian Kualitas ...................................................................................... 6
2.1.1. Faktor Yang Mempengaruhi Kualitas Atau Mutu ............................. 7
2.2. Pengertian Pengendalian Kualitas ............................................................... 8
Analisis Pengendalian..., Agus, Fakultas Teknik 2018
x
2.3. Tujuan Pengendalian Kualitas ..................................................................... 8
2.4. Pengertian Defect ......................................................................................... 9
2.5. Pengertian Produk Not Good (NG) .............................................................. 9
2.6. Pengertian Seven Tools ................................................................................ 9
2.6.1. Lembar Isian (Check Sheet) ............................................................... 10
2.6.2. Diagram Pareto .................................................................................. 11
2.6.3. Diagram Sebab Akibat ....................................................................... 12
2.6.4. Diagram Batang ................................................................................. 14
2.6.5. Diagram Pencar (Scatter) ................................................................... 15
2.6.6. Run Chart ........................................................................................... 16
2.6.7. Peta Kendali (Control Chart) ............................................................. 16
2.7. Definisi Proses Perbaikan ........................................................................... 18
2.8. Pengertian Hidrolik ...................................................................................... 18
2.9. Pengertian PDCA (Plan Do Check Action) ................................................. 19
BAB III METODOLOGI PENELITIAN
3.1. Lokasi Penelitian .......................................................................................... 20
3.2. Teknik Dan Prosedur pengumpulan Data .................................................... 20
3.2.1. Metode Studi Pustaka ........................................................................ 20
3.2.2. Metode Observasi Atau Studi Lapangan ........................................... 21
3.3. Jenis Penelitian ............................................................................................. 21
3.4. Objek Penelitian ........................................................................................... 21
3.5. Pengumpulan Data ....................................................................................... 22
3.6. Pengolahan Data........................................................................................... 22
3.7. Tahapan Definisi .......................................................................................... 23
Analisis Pengendalian..., Agus, Fakultas Teknik 2018
xi
3.8. Tahapan Analisa Dan Pembahasan .............................................................. 23
3.9. Kesimpulan Dan Saran ................................................................................. 24
3.10. Kerangka Penelitian ................................................................................... 25
BAB IV ANALISIS DATA DAN PEMBAHASAN
4.1. Proses Perbaikan Hidrolik ........................................................................... 26
4.1.1. Proses Cutting .................................................................................... 26
4.1.2. Proses Honing .................................................................................... 27
4.1.3. Proses Pembubutan ............................................................................ 27
4.1.4. Proses Pemasangan Seal .................................................................... 28
4.1.5. Tes Uji Kebocoran ............................................................................. 29
4.1.6. Pengecekan Kualitas (Quality Control) ............................................. 29
4.1.7. Proses Packing ................................................................................... 29
4.2. Tahapan Definisi .......................................................................................... 29
4.3. Tahapan Analisa ........................................................................................... 32
4.3.1. Menentukan Tujuan Dan Sasaran (Plan) ........................................... 32
4.3.2. Menentukan Metode Untuk Mencari Akar Permasalahan (Do) ........ 34
4.3.3. Memeriksa Atau Mengevaluasi Aktivitas Perbaikan (Check) ........... 49
4.3.4. Standarisasi Hasil ............................................................................... 41
4.4. Implementasi Hasil....................................................................................... 43
BAB V KESIMPULAN DAN SARAN
5.1. Kesimpulan .................................................................................................. 45
5.2. Saran ............................................................................................................ 46
DAFTAR PUSTAKA
Analisis Pengendalian..., Agus, Fakultas Teknik 2018
xii
DAFTAR TABEL
Halaman
1.1. Data Produk Komplain Cacat ...................................................................... 2
4.1. Data Produk Cacat........................................................................................ 30
4.2. Data Hidrolik OK Dan NG ........................................................................... 31
4.3. Data Check Sheet.......................................................................................... 33
4.4. Tahapan Perbaikan Dari Segi Manusia ........................................................ 37
4.5. Tahapan Perbaikan Dari Segi Mesin ............................................................ 37
4.6. Tahapan Dari Segi Lingkungan ................................................................... 38
4.7. Tahapan Dari Segi Metode........................................................................... 38
4.8. Tahapan Perbaikan Dari Segi Material ........................................................ 39
4.8. Data Produk Cacat Setelah Perbaikan .......................................................... 39
4.9. Data Produk Cacat........................................................................................ 40
4.10.Usulan Standarisasi Hasil ............................................................................ 42
4.11. Data Produk Sesudah Perbaikan ................................................................ 43
Analisis Pengendalian..., Agus, Fakultas Teknik 2018
xiii
DAFTAR GAMBAR
Halaman
1.1. Diagram Pareto Produk Hidrolik Yang Cacat ............................................ 3
2.1. Cheeck Sheet .............................................................................................. 11
2.2. Diagram Pareto ......................................................................................... 12
2.3. Diagram Sebab Akibat ............................................................................... 14
2.4. Diagram Batang (Histogram) .................................................................... 15
2.5. Diagram Pencar (Scatter) .......................................................................... 15
2.6. Run Chart .................................................................................................. 16
2.7. Peta Kendali (Control Chart) .................................................................... 18
3.1. Flow Chart Penelitian ................................................................................ 25
4.1. Proses Pemotongan Tabung Silinder ......................................................... 26
4.2. Proses Honing ............................................................................................ 27
4.3. Proses Pemasangan Seal ............................................................................ 28
4.4. Diagram Pareto Produk Hidrolik Yang Cacat........................................... 31
4.5. Histogram Produk Hidrolik Yang Cacat.................................................... 32
4.6. Histogram Produk Jenis Cacat ................................................................... 34
4.7. Diagram Sebab Akibat Produk Cacat ........................................................ 35
4.8. Data Diagram Produk Cacat ...................................................................... 40
4.9. Diagram Perbandingan .............................................................................. 41
4.10. Diagram Perbandingan Sebelum Dan Sesudah ......................................... 43
4.11. Histogram Perbandingan ........................................................................... 44
Analisis Pengendalian..., Agus, Fakultas Teknik 2018